Fail Of The Week: Machining Bismuth

August 24, 2016 by Jenny List 62 Comments

[David Cook]’s summary below the write-up of his experiences working with a bismuth ingot is succinct.

“I wasted a weekend learning why elemental bismuth is not commonly used for metal parts.“

It’s a fair assessment of his time spent growing unspectacular bismuth crystals, casting a bismuth cylinder that cracked, and machining bismuth only to be left with a very rough finish. But even though he admits the exercise was unsuccessful, he does provide us with a fascinating look at the physical properties of the element.

This is what [David] wanted to make. Alchemist-hp + Richard Bartz with focus stack. (Own work) [CC BY-SA 3.0], via Wikimedia Commons

Bismuth is one of those elements you pass by in your school chemistry lessons, it has applications in machining alloys and as a lead replacement but most of us have never knowingly encountered it in the real world. It’s one of the heavy metals, below antimony and to the right of lead on the Periodic Table. Curious schoolchildren may have heard that like water it expands on solidifying or that it is diamagnetic, and most of us have probably seen spectacular pictures of its crystals coated in colourful iridescent oxides.

It was a Hackaday story about these crystals that attracted [David] to the metal. It has a low enough melting point – 271.5 °C – that it can be liquified on a domestic stove, so mindful of his marital harmony should he destroy any kitchen appliances he bought a cheap electric ring from Amazon to go with his bismuth ingot. and set to work.

His first discovery was that cheap electric rings outdoors aren’t very effective metallurgy furnaces. Relocating to the kitchen and risking spousal wrath, he did eventually melt his bismuth and pick off the top layer once it had resolidified, to reveal some crystals.

Unfortunately for him, instead of spectacular colors and huge crystals, the sight that greeted him was one of little brilliance. Small grey crystals with no iridescence. It seems the beautiful samples are made by a very slow cooling of the liquid bismuth, followed by a quick pouring off of the remaining molten metal. Future efforts, he assures us, will involve sand-insulated molds and careful temperature monitoring.

Undeterred, he continued with his stock of bismuth and embarked on the creation of a cylinder. Early efforts with a clay mold resulted in cracked cylinders, so in desperation he cast the entirety of the metal in an aluminium baking tray and cut the resulting ingot to a rough piece of stock for turning.

With the bismuth in the lathe, he then came face to face with what he alluded to in his conclusion above, why machined bismuth parts aren’t something you’ll encounter. His cylinder came out with significantly rough patches on the surface, because bismuth is both crystalline and brittle. He suggests improvements could be made if the metal could be solidified with fewer crystals, but it’s obvious that elemental bismuth on its own is not a winner in the turning stakes.

We suggest you take a look at [David]’s write-up. It may be presented as a Fail of The Week here, but in fact it’s more of a succession of experiments that didn’t work than an unmitigated disaster. The result is an interesting and well-documented read that we’re sure most Hackaday readers will gain something from.

Aside from the bismuth crystals linked to above, we’ve featured bismuth a few times here at Hackaday. A low-temperature soldering process used it in an alloy, and we’ve even featured someone using it in another alloy to print using a RepRap.

Thanks [nebk] for the tip.

Tools Of The Trade – Test And Programming

August 24, 2016 by Bob Baddeley 15 Comments

In our final installment of Tools of the Trade (with respect to circuit board assembly), we’ll look at how the circuit board is tested and programmed. At this point in the process, the board has been fully assembled with both through hole and surface mount components, and it needs to be verified before shipping or putting it inside an enclosure. We may have already handled some of the verification step in an earlier episode on inspection of the board, but this step is testing the final PCB. Depending on scale, budget, and complexity, there are all kinds of ways to skin this cat.

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Roomba Vs Poop: Teaching Robots To Detect Pet Mess

August 24, 2016 by Adam Fabio 119 Comments

Imagine this: you come home after a day at work. As you open the door, your nose is the first alert that something is very, very wrong. Instead of the usual house smell, your nose is assaulted with the distinctive aroma that means your dog had an accident. The smell is stronger though — as if Fido brought over a few friends and they all had a party. Flipping the lights on, the true horror is revealed to you. This was a team effort, but only one dog was involved.

At some point after the dog’s deed, Roomba, your robot vacuum, took off on its scheduled daily run around the house. The plucky little robot performed its assigned duties until it found the mess. The cleaning robot then became an agent of destruction, smearing a foul smelling mess throughout the space it was assigned to clean. Technology sometimes has unintended consequences. This time, your technology has turned against you.

This scene isn’t a work of fiction. For a select few families, it has become an all too odoriferous reality just begging for a clever fix.

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RGB LEDs: How To Master Gamma And Hue For Perfect Brightness

August 23, 2016 by Elliot Williams 26 Comments

You would think that there’s nothing to know about RGB LEDs: just buy a (strip of) WS2812s with integrated 24-bit RGB drivers and start shuffling in your data. If you just want to make some shinies, and you don’t care about any sort of accurate color reproduction or consistent brightness, you’re all set.

But if you want to display video, encode data in colors, or just make some pretty art, you might want to think a little bit harder about those RGB values that you’re pushing down the wires. Any LED responds (almost) linearly to pulse-width modulation (PWM), putting out twice as much light when it’s on for twice as long, but the human eye is dramatically nonlinear. You might already know this from the one-LED case, but are you doing it right when you combine red, green, and blue?

It turns out that even getting a color-fade “right” is very tricky. Surprisingly, there’s been new science done on color perception in the last twenty years, even though both eyes and colors have been around approximately forever. In this shorty, I’ll work through just enough to get things 95% right: making yellows, magentas, and cyans about as bright as reds, greens, and blues. In the end, I’ll provide pointers to getting the last 5% right if you really want to geek out. If you’re ready to take your RGB blinkies to the next level, read on!

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Colossus: Face To Face With The First Electronic Computer

August 23, 2016 by Jenny List 44 Comments

When the story of an invention is repeated as Received Opinion for the younger generation it is so often presented as a single one-off event, with a named inventor. Before the event there was no invention, then as if by magic it was there. That apple falling on Isaac Newton’s head, or Archimedes overflowing his bath, you’ve heard the stories. The inventor’s name will sometimes differ depending on which country you are in when you hear the story, which provides an insight into the flaws in the simple invention tales. The truth is in so many cases an invention does not have a single Eureka moment, instead the named inventor builds on the work of so many others who have gone before and is the lucky engineer or scientist whose ideas result in the magic breakthrough before anyone else’s.

The history of computing is no exception, with many steps along the path that has given us the devices we rely on for so much today. Blaise Pascal’s 17th century French mechanical calculator, Charles Babbage and Ada, Countess Lovelace’s work in 19th century Britain, Herman Hollerith’s American tabulators at the end of that century, or Konrad Zuse’s work in prewar Germany represent just a few of them.

So if we are to search for an inventor in this field we have to be a little more specific than “Who invented the first computer?”, because there are so many candidates. If we restrict the question to “Who invented the first programmable electronic digital computer?” we have a much simpler answer, because we have ample evidence of the machine in question. The Received Opinion answer is therefore “The first programmable electronic digital computer was Colossus, invented at Bletchley Park in World War Two by Alan Turing to break the Nazi Enigma codes, and it was kept secret until the 1970s”.

It’s such a temptingly perfect soundbite laden with pluck and derring-do that could so easily be taken from a 1950s Eagle comic, isn’t it. Unfortunately it contains such significant untruths as to be rendered useless. Colossus is the computer you are looking for, it was developed in World War Two and kept secret for many years afterwards, but the rest of the Received Opinion answer is false. It wasn’t invented at Bletchley, its job was not the Enigma work, and most surprisingly Alan Turing’s direct involvement was only peripheral. The real story is much more interesting.

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Commanding Kerbals With A Physical Interface

August 23, 2016 by Richard Baguley 16 Comments

Kerbal Space Program will have you hurling little green men into the wastes of outer space, landing expended boosters back on the launchpad, and using resources on the fourth planet from the Sun to bring a crew back home. Kerbal is the greatest space simulator ever created, teaches orbital mechanics better than the Air Force textbook, but it is missing one thing: switches and blinky LEDs.

[SgtNoodle] felt this severe oversight by the creators of Kerbal could be remedied by building his Kerbal Control Panel, which adds physical buttons, switches, and a real 6-axis joystick for roleplaying as an Apollo astronaut.

The star of this build is the custom six-axis joystick, used for translation control when docking, maneuvering, or simply puttering around in space. Four axis joysticks are easy, but to move forward and backward, [SgtNoodle] replaced the shaft of a normal arcade joystick with a carriage bolt, added a washer on one end, and used two limit switches to give this MDF cockpit Z+ and Z- control.

The rest of the build is equally well detailed, with a CNC’d front panel, toggle switches and missile switch covers, with everything connected to an Arduino Mega. This Arduino interfaces the switches to the game with the kRPC mod, which creates a script-driven interface to the game. So, toggling the landing gear switch, for instance, triggers a script which interfaces with KSP to lower your landing gear prior to a nice, safe landing. Or, more likely, a terrifying crash.

Ask Hackaday: Calling All 68k Experts

August 22, 2016 by Brian Benchoff 101 Comments

This is a tale of old CPUs, intensive SMD rework, and things that should work but don’t.

Released in 1994, Apple’s Powerbook 500 series of laptop computers were the top of the line. They had built-in Ethernet, a trackpad instead of a trackball, stereo sound, and a full-size keyboard. This was one of the first laptops that looked like a modern laptop.

The CPU inside these laptops — save for the high-end Japan-only Powerbook 550c — was the 68LC040. The ‘LC‘ designation inside the part name says this CPU doesn’t have a floating point unit. A few months ago, [quarterturn] was looking for a project and decided replacing the CPU would be a valuable learning experience. He pulled the CPU card from the laptop, got out some ChipQuick, and reworked a 180-pin QFP package. This did not go well. The replacement CPU was sourced from China, and even though the number lasered onto the new CPU read 68040 and not 68LC040, this laptop was still without a floating point unit. Still, it’s an impressive display of rework ability, and generated a factlet for the marginalia of the history of consumer electronics.

Faced with a laptop that was effectively unchanged after an immense amount of very, very fine soldering, [quarterturn] had two choices. He could put the Powerbook back in the parts bin, or he could source a 68040 CPU with an FPU. He chose the latter. The new chip is a Freescale MC68040FE33A. Assured by an NXP support rep this CPU did in fact have a floating point unit, [quarterturn] checked the Mac’s System Information. No FPU was listed. He installed NetBSD. There was no FPU installed. This is weird, shouldn’t happen, and now [quarterturn] is at the limits of knowledge concerning the Powerbook 500 architecture. Thus, Ask Hackaday: why doesn’t this FPU work?

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